Foam plug for engine cover fastener pocket

ABSTRACT

An engine cover assembly including a fastener concealing plug is disclosed. The plug includes a conical wall having upper and lower ends. A lower circumferential ring is spaced apart from the upper ring. The lower end of the concealing plug includes a fastener-receiving recessed area. The fastener pocket of the engine cover includes upper and lower grooves having a ring area formed therebetween. The upper circumferential ring of the plug nests with the upper groove of the pocket, the recessed area of the plug nests with the ring area, and the lower circumferential ring of the plug nests with the lower groove of the pocket. The engine cover is positioned on the engine such that a cover attaching stud passes through a stud-passing aperture of the cover. A fastening nut is threaded onto the cover-attaching stud until it comes into contact with a compression-limiting spacer. The plug conceals the fastener.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a divisional application which claims the prioritybenefit of co-pending U.S. patent application Ser. No. 15/363,770, filedNov. 29, 2016, for “Foam Plug For Engine Cover Fastener Pocket,” theentire disclosure of which, including the drawings, is herebyincorporated by reference.

TECHNICAL FIELD

The disclosed inventive concept relates generally to covers for vehicleengines and to a system for attaching the cover to the engine. Moreparticularly, the disclosed inventive concept relates to an engine coverassembly having a mechanical fastener for attaching the cover to theengine and to a foam insert to fill the fastener pocket formed in thecover and to thereby conceal the fastener.

BACKGROUND OF THE INVENTION

The engine compartment of the modern vehicle has an appearance that isquite different from that of its predecessors. For decades following theintroduction of the motor vehicle, the engine compartment was generallyignored by designers who, instead, focused on the exterior and interiorof the vehicle. The engine compartment of the production vehicle (asopposed to the show vehicle) was left entirely to engineers and thus wassolely functional.

Nowadays, however, designers are engaged to improve the overallappearance of the engine compartment. The general result of theseefforts is the inclusion in the engine compartment of an engine coverthat covers at least some of the vehicle's engine. Known covers have avariety of shapes and styles and vary in the degree to which they coverthe engine. The engine cover is typically but not exclusively formedfrom a polymerized material such as soft polyurethane (PUR) foam.

Known methods for attaching the engine cover to the engine itselfinclude fitting stud bolts to strategic locations on the engine,applying appropriate torque to the stud bolts, installing the enginecover having pockets into which the stud bolts are fitted, and runningdown attachment nuts to secure the engine cover in position. The pocketsare formed in the cover to meet the cover's mating component. Thepockets are ordinarily wide enough to meet necessary attachment toolingrequirements.

The exposed fasteners, such as the nut and stud bolt combinationconventionally used to attach the engine cover to the engine, aretraditionally left exposed in their respective pockets. The exposedfasteners do not meet current under-hood appearance requirements.Accordingly, a common challenge for the designer of the modern enginecover is the need to combine functionality and serviceability withaesthetics in the relatively small space typically provided in themodern engine compartment. Consideration must therefore be given to easeof installation to maintain competitive assembly costs and ease ofremovability of the cover while giving assurance that the engine covereffectively provides good aesthetics. Known solutions to attaching theengine cover fail to provide a solution to the challenge faced byexposed fasteners.

As in so many areas of vehicle technology there is always room forimprovement related to the design of engine covers and to their methodsof installation. A new approach to attaching an engine cover to anengine while maintaining optimum aesthetic appearance is needed toaddress the problems associated with known arrangements.

SUMMARY OF THE INVENTION

The disclosed inventive concept provides a convenient, practical andcost-effective solution to the challenge faced by covering mechanicalfasteners that hold the engine cover to the engine. The disclosedinventive concept thus provides an ideal solution to the problem ofappearance degradation caused by the use of mechanical fasteners.

The arrangement of the disclosed inventive concept includes a concealingplug for use in the pocket of an engine cover to hide the mechanicalfastener from view. The concealing plug may be readily installed in thecover pocket and may be easily removed to allow disassembly of the coverfasteners and subsequent removal of the engine cover as needed.

The concealing plug is profiled so as to lockably connect with the wallof the cover pocket. Particularly, the concealing plug includes aconical wall having an upper end and a lower end having afastener-receiving recessed area. The upper end of the concealing plughas a substantially planar outer surface that is continuous with anupper circumferential ring. A lower circumferential ring is spaced apartfrom the upper ring. The lower end of the concealing plug includes arecessed area for receiving the upper end of the fastener when the plugis in position in the pocket. The plug may be composed of any of severalpolymerized materials, such as a polyurethane.

The fastener pocket of the engine cover includes upper and lower grooveshaving a ring area formed therebetween. When the concealing plug isfitted in the cover pocket, the upper circumferential ring of the plugnests with the upper groove of the pocket, the recessed area of the plugnests with the ring area, and the lower circumferential ring of the plugnests with the lower groove of the pocket, thereby providing afluid-tight seal. The base of the pocket includes a stud-passingaperture.

A stud-receiving anchor is attached to the engine and a cover-attachingstud is fitted to the anchor. A compression-limiting spacer is placed onthe upper surface of the anchor. The engine cover is positioned on theengine such that the cover attaching stud is passed through thestud-passing aperture of the cover. A fastening nut is then threadedonto the cover-attaching stud until it comes into contact with thecompression-limiting spacer.

After the fastening nut is fully attached, the concealing plug isinserted without the need for the use of a tool. Removal of theconcealing plug can be easily achieved by using a tool for prying theconcealing plug out of position, such as by use of a screwdriver or asimilar prying tool.

The above advantages and other advantages and features will be readilyapparent from the following detailed description of the preferredembodiments when taken in connection with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

For a more complete understanding of this invention, reference shouldnow be made to the embodiments illustrated in greater detail in theaccompanying drawings and described below by way of examples of theinvention wherein:

FIG. 1 is a side view of the foam plug for an engine cover according tothe disclosed inventive concept;

FIG. 2 is a perspective view of the foam plug of FIG. 1;

FIG. 3 is a top view of a portion of an engine cover illustrating afastener pocket formed therein in which a fastener can be seen beforeinsertion of the concealing foam plug of the disclosed inventiveconcept;

FIG. 4 is the same view of a portion of an engine cover illustrated inFIG. 3 but showing the foam plug of the disclosed inventive concept inplace in the fastener pocket; and

FIG. 5 is a sectional view of a portion of an engine cover and itsengine cover pocket, a portion of an engine, the fastener arrangement bywhich the engine cover is attached to the engine, and the foam plug ofthe disclosed inventive concept in place in the engine cover pocket tothereby conceal the engine cover fastener.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

In the following figures, the same reference numerals will be used torefer to the same components. In the following description, variousoperating parameters and components are described for differentconstructed embodiments. These specific parameters and components areincluded as examples and are not meant to be limiting.

The accompanying figures illustrate an arrangement for providing afinished and clean look to an engine cover for a vehicle. Thefastener-concealing foam plug is readily adapted for any fastenerpocket, is inexpensive to produce, and may be readily inserted into andremoved from the fastener pocket. It is to be understood that theillustrated foam plug as illustrated is not to be restricted to theconfiguration shown in the figures which is intended as beingillustrative without being limiting.

Referring to FIGS. 1 and 2, a fastener-concealing foam plug, generallyillustrated as 10, is shown in isolation. As noted, the illustratedconfiguration of the foam plug 10 as shown in the figures is onlysuggestive and is not intended as being limiting. The concealing foamplug 10 may be formed from any of several polymerized materials,including foamed or solid polymers. The concealing foam plug 10 includesa body 12 having a conical sidewall 14. The body 12 further includes abase wall 16 and a top wall 18.

The fastener-concealing foam plug 10 includes a structure for lockablyand releasably interconnecting with the interior wall of the enginecover pocket. This structure is a ring 20 having an upper ramped surface22 and a lower ramped surface 24. The configuration of the rampedsurfaces 22 and 24 allow the fastener-concealing foam plug 10 to bereadily inserted and removed from the fastener pocket.

Referring to FIG. 3, a top view of a portion of an engine cover 30having a fastener pocket 32 is illustrated. As is known, the enginecover 30 may be made from any of several materials including, withoutlimitation, polyurethane. Several fastener pockets 32 may be formed inthe engine cover 30 though only a fastener pocket 32 is illustrated forthe sake of simplicity.

The fastener pocket 32 includes an upper shoulder 34 and a lowershoulder 36. A base wall 38 is formed at the lower end of the fastenerpocket 32. While a variety of methods mechanically fastening the enginecover 30 to the engine may be used, a preferred method is illustrated asincluding an engine cover stud 40 onto which a fastening nut 42 may bethreaded.

Referring to FIG. 4, a top view of a portion of the engine cover 30 isalso illustrated. However, in this view, the fastener-concealing foamplug 10 has been securely fitted into the fastener pocket 32. Asillustrated in FIG. 4, the presence of the fastener-concealing foam plug10 gives the engine cover 30 a finished and clean look withoutcompromising the removability of the engine cover 30. Thefastener-concealing foam plug 10 may be readily installed into thefastener pocket 32 upon vehicle assembly or following engine servicing.When engine service is required, the service technician may easilyremove the fastener-concealing foam plug 10 by a simple operation usinga basic tool such as a screwdriver or a small pry bar.

A sectional view of the fastener-concealing foam plug 10 installed inthe fastener pocket 32 and the accompanying fastening hardware isillustrated in FIG. 5. With reference thereto, the fastener pocket 32includes an upper recess 50 defined by the upper shoulder 34. An innerring 52 is formed adjacent the upper shoulder 34. A recessed area 54 isformed between the inner ring 52 and the lower shoulder 36. A lowerconical wall 56 is formed between the lower shoulder 36 and the basewall 38.

The engine cover 30 includes bottom wall 58 formed on the underside ofthe fastener pocket 32. When in position, the engine cover 30 is fittedadjacent an engine block 60. A fastener anchor 62 is attached to theengine block 60 into which the engine cover stud 40 is threaded or isotherwise attached. The nut 42 is threaded onto the upper end of theengine cover stud 40. A spacer 64 is fitted between the underside of thenut 42 and the upper side of the fastener anchor 62. The spacer 64 alsofunctions as a load limiter. With the spacer 64 in place, a gap ispreferably defined between the engine block 60 and the bottom wall 58 ofthe cover 30. A recessed area 66 is defined within the central area ofthe base wall 16. The recessed area 66 provides an open area withinwhich the upper end of the engine cover stud 40 and the nut 42 arepositioned when the fastener-concealing foam plug 10 is in positionwithin the fastener pocket 32.

The fastener-concealing foam plug 10 is retained in position within thefastener pocket 32 by the outer side wall profile of thefastener-concealing foam plug 10 which securely engages the inner wallprofile of the fastener pocket 32. Particularly, when thefastener-concealing foam plug 10 is in position in the fastener pocket32, the top wall 18 rests within the upper recess 50 and against theupper shoulder 34, thereby halting further downward movement of the plug10 upon insertion into the pocket 32 after the plug 10 has reached itsmaximum insertion depth. At the same time, the ring 20 of the plug 10engages and rests within the recessed area 54. The conical sidewall 14of the plug 10 nests against the lower conical wall 56 of the pocket 32formed between the lower shoulder 36 and the base wall 38.

Because of the elastomeric qualities of the fastener-concealing foamplug 10, when the plug is in position within the pocket 32 it tends tofill the space defined by the pocket 32, thereby maintaining the plug 10securely within the pocket 32 until a repair technician selects toremove the plug 10 from the pocket 32 for servicing. This sameelastomeric quality provides fluid-tight seal that prevents water, oiland debris from accumulating in the pocket 32 and near the fastenerassembly. Furthermore, the resilient nature of the plug 10 permitsrepeated reuse of the plug 10.

One skilled in the art will readily recognize from such discussion, andfrom the accompanying drawings and claims that various changes,modifications and variations can be made therein without departing fromthe true spirit and fair scope of the invention as defined by thefollowing claims.

What is claimed is:
 1. A cover assembly for use with a vehicle enginecomprising: a cover having a fastener pocket; a fastener for attachingsaid cover to the engine; and a plug for removable insertion into saidpocket, said plug including an upper end and a lower end, said lower endhaving a fastener-receiving recessed area, said plug further includingan upper circumferential ring, a lower circumferential ring, acircumferential groove formed between said upper and lowercircumferential rings, and a conical wall formed between said lowercircumferential ring and said lower end.
 2. The removable plug of claim1 wherein said upper end includes an outer top surface, said outer topsurface being substantially planar.
 3. The removable plug of claim 1wherein said lower end has an outer surface and said fastening-receivingrecessed area is formed in said outer surface.
 4. The removable plug ofclaim 3 wherein said outer surface of said lower end has a center andsaid fastener-receiving recessed area is formed in said center.
 5. Theremovable plug of claim 1, the plug being formed from a polymerizedmaterial.
 6. The removable plug of claim 5 wherein said polymerizedmaterial is a polyurethane.
 7. A cover assembly for use with a vehicleengine comprising: a cover having a fastener pocket; a fastener forattaching said cover to the engine; and a plug for removable insertioninto said pocket, said plug including upper and lower ends, said lowerend having a fastener-receiving recessed area, said plug furtherincluding a conical wall formed between said upper end and said lowerend, a circumferential ring formed on said conical wall defining saidupper end, and a retention ring formed on said conical wall between saidcircumferential ring and said lower end.
 8. The removable plug for anengine cover of claim 7 wherein said upper end includes an uppersurface, said upper surface being substantially planar.
 9. The removableplug for an engine cover of claim 8, wherein said circumferential ringis adjacent said outer surface of said upper end, said circumferentialring being continuous with said planar surface.
 10. The removable plugfor an engine cover of claim 7 wherein said retention ring comprises afirst circumferential recessed area, a second circumferential recessedarea, and a circumferential ring formed between said first and secondrecessed areas.
 11. The removable plug for an engine cover of claim 10wherein said first circumferential recessed area is a circumferentialgroove.
 12. The removable plug for an engine cover of claim 10 whereinsaid first circumferential recessed area is formed adjacent saidcircumferential ring.
 13. The removable plug for an engine cover ofclaim 7 wherein said lower end has an outer surface and saidfastener-receiving area is formed on said outer surface.
 14. Theremovable plug for an engine cover of claim 13 wherein said lower areahas a center and said fastener-receiving recessed area is formed in saidcenter.
 15. A cover assembly for use with a vehicle engine comprising: acover having a fastener pocket including upper and lower grooves and aring therebetween; a fastener for attaching said cover to the engine;and a plug for removable insertion into said pocket, said plug includingan upper circumferential ring matable with said upper groove, a lowercircumferential ring matable with said lower groove, and acircumferential ring matable with said ring of said pocket.
 16. Thecover assembly for use with a vehicle engine of claim 15, wherein saidpocket includes a conical internal wall and said plug includes a conicalexternal wall matable with said conical internal wall of said pocket.17. The removable plug for an engine cover of claim 15, wherein saidplug includes a lower end having a fastener-receiving recessed formedtherein.
 18. The removable plug for an engine cover of claim 15, furtherincluding a fastener anchor attached to the engine for receiving saidfastener, said fastener anchor having an upper surface.
 19. Theremovable plug for an engine cover of claim 18, wherein said fastenerincludes a stud and a nut, said stub being inserted into said fasteneranchor.
 20. The removable plug for an engine cover of claim 19, furtherincluding a compression limiting spacer positioned between said uppersurface of said fastener anchor and said nut.